Compression molding is among the types of fabrication processes specifically used for intricate components and advanced composite structures. This molding process is particularly chosen when working with thermoplastic Bulk Molding Compounds (BMC). This blog highlights the variety of reasons why compression molding is chosen for such operations.
Understanding Thermoplastic Bulk Molding Compounds
Thermoplastic BMCs are alternative materials to thermoset BMCs. They are known as melt processable plastics, which mean they can be processed using heat.
Thermoplastics melt into liquids easily when exposed to temperatures above their melting points. Also, they solidify just as quickly when the temperature is lower than the melting point, or is brought down to freezing point. This makes thermoplastics ideal for creating industrial plastic products.
They are particularly useful for sectors and applications, where there is a huge demand for:
- High durability
- Faster component production
- Materials that have low flame and toxicity levels
Examples of thermoplastic composites include polypropylene, fiberglass, and PEEK.
Why Use Compression Molding with Thermoplastic BMCs ?
The following reasons showcase why it is beneficial to use compression molding to create components and products from thermoplastic BMCs.
- Compression molding involves the use of loose chips or strands of thermoplastic materials. These strands are aggregated by weight to meet volume requirements for molding a component. The heat and compression from the molding process allows the fibers to melt and flow easily. They are able to fill all the intricate crevices of the mold, thus allowing for the production of intricate components.
- Compression molding is a better alternative than injection molding. Injection molding utilizes woven fabric prepregs – continuous fiber composites. While these composites can provide a certain level of stiffness and strength, they are limited when creating components with complex geometries.
- The fast melting and solidifying capabilities of Thermoplastic BMCs allows for the production of industrial plastic components with high levels of strength and stiffness.
It is for the above mentioned reasons that compression molded thermoplastic components are extremely popular in industries such as aerospace, automotive, and defence. Hence, if you are looking at creating thermoplastic components with complex designs and geometries, it would be wise to ask for compression molding as the production method.
